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Research · Minivan - 2WD

2004 Ford FreestarRecalls, problems, MPG & safety

NHTSA lists 5 safety recalls and 1,227 owner complaints for the 2004 Ford Freestar. Most complaints involve power train (851) and electrical system (118). The EPA rates it 17–18 mpg combined.

Check a VINAdd to my garage
Combined MPG
17–18mpg
EPA · 3 versions
NHTSA overall
—
Not rated by NCAP
Safety recalls
5campaigns
Latest Mar 2013
Owner complaints
1,227
Top: power train
Fuel cost / yr
$3,450est.
EPA estimate, best version
01 —Recalls

Safety recalls

5 NHTSA campaigns · applies to some vehicles, check your VIN

Seats

Free remedy

Ford is recalling certain model year 2004-2007 Freestar and Mercury Monterey vehicles manufactured from March 24, 2003, through November 7, 2006, equipped with a third row seat and originally sold in, or currently registered in, Connecticut, Delaware, Illinois, Indiana, Iowa, Maine, Maryland, Massachusetts, Michigan, Minnesota, Missouri, New Hampshire, New Jersey, New York, Ohio, Pennsylvania, Rhode Island, Vermont, West Virginia, Wisconsin and the District of Columbia. The third row stowable seat can experience corrosion and structural degradation at the seat anchor mechanism mounted to the rear wheel wells. As a result of the corrosion, the third row seat may not fully latch into its seating position.

SeatsReported Mar 7, 2013NHTSA 13V081000

Power train: automatic transmission

Free remedy

FORD IS RECALLING CERTAIN MODEL YEAR 2004 AND 2005 FORD FREESTAR AND MERCURY MONTEREY VEHICLES. THE TORQUE CONVERTER OUTPUT SHAFT MAY FAIL.

Power trainReported Jan 9, 2012NHTSA 12V006000

Fuel system, gasoline

Free remedy

CERTAIN AFTERMARKET FUEL FILTERS SOLD UNDER THE PUROLATOR BRAND NAME, P/N F65277, SHIPPED FROM JANUARY 16 THROUGH JUNE 2, 2006, FOR USE ON THE ABOVE LISTED PASSENGER VEHICLES. DUE TO INCORRECT DESIGN, THE QUICK CONNECTORS MAY NOT FULLY SEAT WITH THE TUBE INTERFACE, EVEN THOUGH THE PERSON MAKING THE CONNECTION MAY BELIEVE THAT THE QUICK CONNECTOR IS FULLY ATTACHED.

Fuel system, gasolineReported Jun 13, 2006NHTSA 06E056000
See all 5 recalls with remedies
Data from NHTSA Recalls API · synced Nov 10, 2026 · All recall detailsNHTSA vehicle page
02 —Complaints

Owner complaints by component

1,227 complaints filed with NHTSA · Mar 2004 – Jul 2025
  1. Power train851
  2. Electrical system118
  3. Structure94
  4. Seats86
  5. Engine69
  6. Engine and engine cooling49
  7. Service brakes, hydraulic44
  8. Vehicle speed control33
  9. Steering27

Complaints are unverified owner reports to NHTSA and are not normalized for sales volume. One complaint can cite several components.

By model year

Complaints for each Freestar model year we’ve synced.

View as table
Model yearNHTSA complaints
20041,227
2005886
2006356
200764
Crashes reported
16
Fires reported
14
Injuries reported
21
Deaths reported
1
Data from NHTSA Complaints API · synced Nov 10, 2026 · Full problem breakdownNHTSA vehicle page
03 —Common problems

What owners report most

Verbatim excerpts from NHTSA complaints, by component

Power train

851 reports6 crashes7 fires
“The contact owns a 2004 Ford Freestar. The contact stated while driving at approximately 40 MPH, the vehicle stalled. There was no warning light illuminated. The vehicle was towed to the residence. An independent mechanic diagnosed that the torque converter and the transmission needed to be replaced. The contact related the failure to an unknown NHTSA Campaign Number; however, the VIN was not included. The vehicle was not repaired. The manufacturer was notified of the failure. The failure mileage was approximately 104,000.”
Owner complaint to NHTSAFiled Jul 11, 2025Power trainODI 11672730

Electrical system

118 reports2 crashes1 fire
“The transmission is grinding and popping when shifting gears.Also it has started not moving when I shift it into drive and 3rd and 1st.When I drive it I have to put it in 1st gear and change up to drive and it grinds and pops when giving it gas to go.It comes to a crawl going up hills.Has a big loss of power.The trackshion control light comes on saying it's not working.The electrical is messing up the doors are opening up when they are not supposed to going down road.It tells me that different doors are open when there not keeping the lights on in the van running down the battery.”
Owner complaint to NHTSAFiled Jan 18, 2023Power train, Electrical system, Back over preventionODI 11502520

Structure

94 reports1 crash1 fire
“THE PART THAT HAS THE CLIP FOR BACK SEAT FELL OUT AND NOW THERE IS A 5 BY 5 INCH HOLE GOING INTO THE WHEEL WELL AND THE SEAT HAS NOTHING TO CLIP ONTO AND BE SECURE, THIS WAS RECALLED IN THIS MODEL”
Owner complaint to NHTSAFiled Dec 3, 2020Structure, SeatsODI 11377831
All 2004 Freestar problemsSend a problem to a mechanic on findmechanic.ai
Data from NHTSA Complaints API (owner reports, unverified) · synced Nov 10, 2026
04 —Key specs

Engines, transmissions & drive

3 versions rated by the EPA
EPA class
Minivan - 2WD
Engines
3.9L 6-cyl · 4.2L 6-cyl
Transmissions
Automatic 4-spd
Drive
Front-Wheel Drive
Fuel
Regular Gasoline

Towing, payload and dimensions aren’t in the EPA or NHTSA data, so we don’t list them.

Data from EPA fueleconomy.gov · synced Nov 10, 2026EPA listing
05 —Fuel economy

EPA fuel economy by version

City / highway / combined, annual fuel cost and CO₂
EPA
VersionCityHwyComb.Fuel / yrCO₂ g/mi
Freestar Cargo Van FWD
Auto 4-spd, 6 cyl, 3.9 L · Front-Wheel Drive
152118$3,450494
Freestar Wagon FWD
Auto 4-spd, 6 cyl, 3.9 L · Front-Wheel Drive
152117$3,650523
Freestar Wagon FWD
Auto 4-spd, 6 cyl, 4.2 L · Front-Wheel Drive
152117$3,650523
Estimate your fuel costCost of ownership
Data from EPA fueleconomy.gov · synced Nov 10, 2026 · Fuel cost is EPA’s annual estimate (15,000 mi, 55% city)
06 —Safety

NHTSA 5-Star Safety Ratings

1 tested variant
NHTSA has not published 5-Star Safety Ratings for the 2004 Ford Freestar as of Nov 10, 2026.
Data from NHTSA NCAP Safety Ratings API · synced Nov 10, 2026Vehicle 1126
07 —Maintenance

Maintenance basics

General guidance, not the OEM schedule. Check your owner’s manual.
General guidance
ItemMilesTimeNote
Engine oil & filter5,000–10,000 mi6–12 monthsFollow the oil-life monitor if fitted
Tire rotation5,000–7,500 miEvery oil changeCheck pressure monthly
Engine air filter15,000–30,000 mi1–2 yearsSooner in dusty areas
Cabin air filter15,000–25,000 mi1–2 years
Brake fluid—2–3 yearsAbsorbs moisture over time
Coolant60,000–100,000 mi5–10 yearsLong-life coolants last longer
Spark plugs60,000–100,000 mi—Iridium/platinum plugs at the long end
12V battery—3–5 yearsHeat shortens battery life
  • Engine oil & filter5,000–10,000 mi
    6–12 months
  • Tire rotation5,000–7,500 mi
    Every oil change
  • Engine air filter15,000–30,000 mi
    1–2 years
  • Cabin air filter15,000–25,000 mi
    1–2 years
  • Brake fluid—
    2–3 years
  • Coolant60,000–100,000 mi
    5–10 years
  • Spark plugs60,000–100,000 mi
    —
  • 12V battery—
    3–5 years
Typical intervals for modern cars. Severe service (towing, short trips, extreme heat or cold) shortens them.
09 —FAQ

2004 Freestar questions

How many recalls does the 2004 Ford Freestar have?

5 safety recalls as of Nov 10, 2026, according to NHTSA. Recall repairs are free at a dealer. Check your VIN to see whether your car is included and whether the repair was done.

What are the most common 2004 Ford Freestar problems?

Owners filed 1,227 complaints with NHTSA. The most-cited components are power train (851), electrical system (118), structure (94). Complaints are unverified owner reports and aren't adjusted for how many cars were sold.

What MPG does the 2004 Ford Freestar get?

The EPA rates the 2004 Ford Freestar at 17–18 mpg combined, depending on engine and drivetrain (3 versions rated).

Data from NHTSA & EPA · synced Nov 10, 2026